Water-softening and regeneration process

ABSTRACT

A water-softening system for washing machines and the like which comprises a regeneration chamber in direct circuit between the water supply and an ion-exchange chamber which is, in turn, in direct circuit with the washing machine tub. Normally, there is no regeneration material in the regeneration chamber so that water flows directly through to the ion-exchange chamber, where it is softened, and then into the tub. When it is necessary to regenerate the ion-exchange resin, regeneration material, either granular or fluid, is inserted into the regeneration chamber and the water from the source is permitted to flow for a brief interval sufficient to carry the regeneration material into the ion-exchange chamber. It is permitted to stay in the ion-exchange chamber for sufficient time to regenerate the ion-exchange resin and is then flushed out through the tub into the drain. No special control valves or other control means are necessary for the regeneration cycle.

United States Patent Borochaner WATER-SOFTENING AND REGENERATION PROCESS Stuart Borochaner, Levittown, Pa.

National Water Pure Corporation, Burlington, NJ.

Filed: Marclr26, 1971 Appl. No.: 128,313

Related U.S. Application Data Division of Ser. No. 852,293, Aug. 22, 1969.

[72] Inventor:

[73] Assignee:

[56] References cm 1 UNITED STATES PATENTS 3,148,687 9/1964 Dosch ..68/l3 A X 3,385,441 5/1968 Lyall.....- ..68/13 A 3,544,371 12/1970 Zinkanin ..68/13 A Primary Examiner- Samih N. Zaharna Attorney-Arthur A. Jacobs ABSTRACT A water-softening system for washing machines and the like which comprises a regeneration chamber in direct circuit between the water supply and an ionexchange chamber which is, in turn, in direct circuit with the washing machine tub. Normally,'there is no regeneration material in the regeneration chamber so that water flows directly through to the ion-exchange chamber, where it is softened, and then into the tub. When it is necessary to regenerate the ion-exchange resin, regeneration material, either granular or fluid, is inserted into the regeneration chamber and the water from the source is permitted to flow for a brief interval sufficient to carry the regeneration material into the ion-exchange chamber. It is permitted to stay in the ion-exchange chamber for sufficient time to regenerate the ion-exchange resin and is then flushed out through the tub into the drain. No special control valves or other control means are necessary for the regeneration cycle.

2 Claims, 4 Drawing Figures SOI'TNER PATENTEDAus' 1 Inn y 3.680.703

SHEEI 1 or 2 rue SOFTNER v 36 46 j 4 4 STUART BOROCHA/VER F IG. 4

PATENTEDAUG 1 1972 3,680,703

sum 2 or 2 V so; TNER $7 UART BO/POCHA IVER WWW WATER-SOFTENING AND REGENERATION PROCESS This is a division of co-pending application Ser. No. 852,293, dated Aug. 22, 1969. This invention relates to a water-softening system, and it particularly relates to a water-softening system utilizable in an automatic washing machine.

It has long been known that hard water, i.e., water that contains relatively large amounts of calcium and magnesium, is undesirable for most household purposes such as cooking, washing,-and the like. It is known that fabrics which have been washed in detergent solutions of hard water are not as soft and pliable as fabrics that have been washed in soap solutions of soft water because detergents tend to remove the natural oils and moisture from the fibers of the fabrics.

However, in hard water, it is necessary to use a great amount of detergents, even when using soap, because, otherwise, there is a tendency for the soaps to react with the calcium or magnesium ions to form insoluble salts which precipitate upon the fabrics.

in order to overcome the aforementioned problems, it was heretofore proposed to provide a mechanism within the machine itself that was constructed to automatically soften the water as it flowed through the machine into the washing tub therein. This mechanism included an ion-exchange chamber through which the water passed prior to entering the tub and means to pass regenerating material through the ion-exchange chamber to regenerate the ion-exchange material and maintain it in ready condition for each flow of water therethrough. This was all accomplished automatically during the machine cycles.

The above-described ion-exchange system, which is embodied in applicants US. Pat. No. 3,204,767, proved to be an important advance over prior systems. However, it required a large number of valves, solenoid operating means for the valves, and a relatively complicated piping system which not only materially increased the cost of the machine but also provided increased possibility of breakdowns due to malfunctioning of the valves and solenoids. An especial problem was that if a solenoid valve was used between the water system and the tub, if a break should occur in the water main and if the valve should malfunction at the same time, the sewerage from the drain line would be sucked back into the water system.

It was, heretofore, not possible to eliminate all these valves, and especially the control valve for the regeneration fluid, and still have an operative and efficient system. This regeneration control valve was a particular problem because the regenerating fluid is a brine, such as sodium chloride solution. It was found that this brine, within a relatively short time, caused caking and corrosion of the valve, which, thereupon, began to constantly stick and ultimately became inoperable. As a result, it was necessary to continually clean and ultimately replace the valve after a relatively short period of use.

Furthermore, the piping in the system of the aforesaid patent, as well as in all other prior systems, was relatively complicated since not only was a separate line required for passage of the regeneration fluid to the ion-exchange chamber, and not only was a solenoid valve required in this line, but if the regeneration fluid chamber was to be supplied with water from the system to form the aqueous regeneration fluid, either a separate line was required from the source of water or a complicated double-action valve was required. The alternative was to make the solution outside the machine and then pour the solution itself into the regeneration chamber. This was undesirable since it required extra effort to which the ordinary housewife might sometimes object. It would be much simpler to merely insert the required amount of dry salt into the chamber whenever required.

As is readily apparent, the complex piping and the presenceof the various valves not only increased the initial cost as well as the cost of maintenance of the machine, but also required additional space. This additional space was a problem in the case of small, relatively portable machines, where every amount of space and weight had to be utilized most economically.

It is, therefore, one object of the presentinvention, to provide a water-softening system for washing machines and the like where all valving, and especially the control valve for the ion-exchange regenerating circuit, is eliminated.

Another object of the present invention is to provide a simple, straight-through flow water-softening system wherein the piping is reduced to a minimum with a consequent saving of space, weight and maintenance.

Another object of the present invention is to provide a system of the aforesaid type wherein the regeneration chamber is supplied with water for the brine solution directly from the source of water and without the necessity for using any by-pass piping.

Other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following description when read in conjunction with the accompanying drawings wherein:

FIG. 1 is a schematic view of one embodiment of the present invention.

FIG. 2 is a partially schematic and partially elevational view of a simplified construction of the present invention.

FIG. 3 is a sectional view of the combined ionexchange and regenerating unit shown in FIG. 3.

FIG. 4 is a schematic view of an optional feature in i the regeneration chamber construction.

Referring now in greater detail to the various figures of the drawings wherein similar reference characters refer to similar parts, there is shown in FIG. 1 a system, generally designated 10, comprising a mixing valve 12, constituting the source of water for the system. Hot and cold water lines 14 and 16 lead into the valve 12 from sources (not shown) which would ordinarily be the hot and cold water lines of the house or other building. The valve 12 is actuated by a solenoid 18 electrically connected' by lines 20 and 22 to a timer mechanism hereinafter described.

A conduit 24 leads from the mixing valve 12 into the regeneration chamber 26. The chamber 26 is adapted to hold regeneration fluid for regenerating the ionexchange resin after a period of use. This chamber 26 may have a removable or hinged lid for insertion of the regenerating material. This material is preferably granular, such as granular sodium chloride, but may be liquid if desired.

A conduit 28 leads from the regenerating chamber 26 to the ion-exchange chamber 30 which contains a supply of ion-exchange resin .for softening the water. This ion-exchange resin may be of any standard type.

A conduit 32 leads to an inlet 34 into the inner tub 36 of the washing machine. An air break 38, of standard construction, is interposed in the conduit 32, prior to the inlet 34. This air break 38 is provided for the purpose of preventing back flow into the ion-exchange chamber 30 from the tub 36 in the event of a break or rupture in the conduit, and is, therefore, in effect, a one-way valve means.

, A drip line 40 of relatively narrow diameter, leads fromthe conduit 24 into the tub 36. However, if desired, the drip line 40 may alternatively lead directly to the drain line of the pump hereinafter described. A line 42, of similar diameter, leads from the conduit 32, adjacent to, the air break 38, into the regenerating chamber 26, above the conduit 28. Alternatively, the conduit 42 may lead ,to the tub 36 or be open directly to atmosphere. A pump.44 is connected to the tub 36, this pump being connected to a drain pipe 46 in the ordinary manner. a

The machine is actuated by a standard-type timer control means, indicated generally at 48. This timer mechanism may comprise any standard type now in use, as, for example, that disclosed in US. Pat. No. 3,204,767 or in [1.8. Pat. No. 2,434,353. This timer mechanism causes the usual agitation, rinse and spin steps to occur in the desired succession. A separate timer circuitmay beprovided to activate and deactivate the water supply valve 12 and the pump 44 during the regeneration cycle. Such timer circuit would be similar to that used for theregular'cycles. Altematively, themain timer mechanism may beprovided with an additional regeneration cycle which is selectively actuated by a separate switch.

During the operation of the'system, the water from the mixing valve 12 always flows, through the regeneration chamber 26 as wellas through the ion-exchange chamber 30 before entering the tub 36. In this manner, all thewater used is first softened by the ion-exchange .resin in chamber'30. However, .itis not necessary to regenerate this resin each time. Only after a predetermined period of use is this necessary. A label with instructions for they periods of regeneration may be attached to the machine as a guide to the user.

Since regeneration is required only at predetermined intervals, in the usual operation of the machine, the waterflows through the chamber 26 while it is empty. When regenerationis required, the user inserts the necessary amount of salt into the chamber 26, and pushes :thebutton for regeneration cycle. This activ'ates the timing mechanism to open the valve 12 to In order to permit the user to easily open the lid of the regeneration chamber 26, which'might otherwise be hampered by'the presence of fluid inthe system when the machine is inoperative, the drip line 40, which is always open, acts as a fluid relief means. However, in order to permit this drip line to function properly, the vent line 42 is provided. This line receives air from the air break 38 or from atmosphere if it is so constructed and arranged, and causes it to flow into the regeneration chamber 26. This permits the drip line to operate at all times.

The above-described operation of the regeneration cycle, utilizes no control valves and no moving parts other than the mixing valve and the'pump; The mixing valve is, of course, never touched by theregeneration or salt solution, while the solution which does flow through the pump is so diluted'by the time it reaches thepump that no build-up or encrustation of the pump is possible. At the same time, the water which constantly flows through the regeneration chamber 26, even when there is no salt present therein, acts to keep it always clean and unclogged. I a v FIGS. 2 and 3 illustrate'a simplified construction utilizing the general system of FIG. -1 wherein the system, generally designated 200, comprises the mixing valve 202, which isprovided with a solenoid204 electrically connected by lines 205 and 206 to the timing mechanism (not shown). A conduit 208 connects the valve202 to an ion-exchange'chamber 210 having an upstanding dispensing housing or hopper 212 integrally connected thereto. The hopper 212 is provided with a removable lid 214.- Y

A conduit 216 extends from the ion-exchange chamber 210 to an inlet for the tub '218. An air break. 220 is interposed in the conduit 216. A drip line 222 leads'from the bottom of the chamber 210, while a pressure relief line 224 leads from the ;top --jof the chamber 2l0 to the'conduit 216adjacent to the air a break 220, or, alternatively, to the tubv or directly to atmosphere.,A pump 226, having a drain line 228, is provided at the bottom of the tub.

In this construction, the hopper 214 is used 'forinser-' tion of the regeneration salt when required, andthe is open, a normally open switch may be provided on the mouth of the chamber which is closed when the lid is.

closed. This switch would be in the solenoid-circuit of time. In this manner, all the excess salt is flushed out of the system p'n'or tothe next washing cycle.

tion chamber 300 is provided with a normally open switch 302 having leads 304 connected to the solenoid circuit (not shown).-The lid 306 which is hinged to the chamber 300 at 308, has a lug 3l0 which depresses the switch into closed position when the lid is closed.

I claim:

l. A method of operating a system comprising a regeneration chamber, an ion-exchange chamber and a washing machine having a wash tub, all being connected in series with each other and said regeneration chamber being above the inlet to said washtub, and wherein the system includes means for controlling the water from a water source to said regeneration chamber and drain means operatively connected to said wash tub, which comprises, during the operation of the washing machine, passing the water from said source through the regeneration chamber, said regeneration chamber being adapted to selectively hold regeneration material, then through said ionexchange chamber containing an ion-exchange resin, andthen through a one-way valve means into said wash tub, the flow of said water from said source through said regeneration chamber and through said ion-exchange chamber to said one-way valve means being direct and uninterrupted by any valves, and the flow of said water from said one-way valve means into saidwash tub also being direct and uninterrupted by any valves, and periodically regenerating the ion-exchange resin by first terminating the flow of water from said source, then draining the water from said regeneration chamber through said drain means by gravity, thereafter inserting regeneration material into said regeneration chamber, and then passing water from said source through said regeneration chamber and through both said ion-exchange chamber and said wash tub to said drain means.

2. The method of claim 1 wherein the draining of the water from said regeneration chamber comprises a flow through said ion-exchange chamber and through said wash tub prior to passage of the flow through said drain means. 1 

1. A method of operating a system comprising a regeneration chamber, an ion-exchange chamber and a washing machine having a wash tub, all being connected in series with each other and said regeneration chamber being above the inlet to said wash tub, and wherein the system includes means for controlling the water from a water source to said regeneration chamber and drain means operatively connected to said wash tub, which comprises, during the operation of the washing machine, passing the water from said source through the regeneration chamber, said regeneration chamber being adapted to selectively hold regeneration material, then through said ion-exchange chamber containing an ion-exchange resin, and then through a one-way valve means into said wash tub, the flow of said water from said source through said regeneration chamber and through said ion-exchange chamber to said one-way valve means being direct and uninterrupted by any valves, and the flow of said water from said one-way valve means into said wash tub also being direct and uninterrupted by any valves, and periodically regenerating the ion-exchange resin by first terminating the flow of water from said source, then draining the water from said regeneration chamber through Said drain means by gravity, thereafter inserting regeneration material into said regeneration chamber, and then passing water from said source through said regeneration chamber and through both said ionexchange chamber and said wash tub to said drain means.
 2. The method of claim 1 wherein the draining of the water from said regeneration chamber comprises a flow through said ion-exchange chamber and through said wash tub prior to passage of the flow through said drain means. 